{"id":33785,"date":"2026-09-23T10:00:00","date_gmt":"2026-09-23T09:00:00","guid":{"rendered":"https:\/\/www.engineernewsnetwork.com\/blog\/?p=33785"},"modified":"2026-09-22T10:42:25","modified_gmt":"2026-09-22T09:42:25","slug":"hot-spots-usually-start-with-an-airflow-problem","status":"publish","type":"post","link":"https:\/\/www.engineernewsnetwork.com\/blog\/hot-spots-usually-start-with-an-airflow-problem\/","title":{"rendered":"Hot spots usually start with an airflow problem"},"content":{"rendered":"\n

Joshua Baxely explains how persistent facility hot spots can result from airflow distribution, system resistance, fan controls, and changing heat loads, highlighting electronically commutated (EC) fans, variable-speed control, and fan arrays as potential solutions. This is relevant to industrial facilities because equipment-heavy production environments can generate significant and changing heat loads, making effective airflow, energy-efficient fan control, redundancy, and reliable ventilation important for maintaining stable operating conditions and supporting productivity<\/strong><\/p>\n\n\n\n

When a facility stays hot despite active ventilation, the answer is not always a larger fan or more equipment. The fan system may be moving air, but still failing to deliver that air where the heat is concentrated, push it through the actual resistance in the system, or respond as operating conditions change. For facility teams, that distinction matters. Adding airflow without understanding the air path can raise energy use without solving the temperature problem.<\/p>\n\n\n\n

A better diagnosis starts with a more precise question: is the fan system delivering the required airflow, at the required static pressure, to the areas where heat is building? A restricted return path, loaded filters, unexpected duct resistance, or a concentrated equipment load can all leave a fan looking operational while the facility continues to run hot. A fan can be running and still fall short if its control strategy, airflow path, and capacity no longer align with the facility\u2019s actual heat load.<\/p>\n\n\n\n

That mismatch is becoming more common as facilities grow denser. Data centres, commercial mechanical spaces, and industrial environments now contain more electronic equipment, tighter layouts, and higher internal heat gains than many ventilation systems were originally designed to handle. A system that once performed well may begin to struggle as heat loads shift, equipment mixes change, or the air path becomes more restrictive over time.<\/p>\n\n\n

\n
\"\"<\/a>
Persistent hot spots often come from airflow direction, system resistance, fan control, and heat load, not simply from a lack of fan capacity<\/em><\/figcaption><\/figure>\n<\/div>\n\n\n

Persistent heat is often treated as a capacity problem, but the first diagnostic question is whether the delivered air is doing useful work. A fan may meet its selected operating point and still leave parts of the facility hot if the air path is poorly controlled. Supply air can return too quickly without sweeping the occupied or equipment dense zone. Heat can build in areas where circulation is weak. A restricted return path can also limit total system volume, leaving the fan with less air to move through the space than the design assumes. <\/p>\n\n\n\n

Static pressure is where many of those problems become measurable. Ductwork, filters, coils, dampers, guards, and discharge conditions all add resistance to the airstream. As that resistance increases, the fan may shift away from the point on the curve where the system was originally designed to operate. Loaded filters are a common example: as pressure drop rises, the fan must work against a different system condition than it did when the filters were clean. If the fan cannot maintain the required airflow at that higher resistance, the space can continue to heat up even while the equipment appears to be running normally.<\/p>\n\n\n\n

That is why facility teams need a measurement set before making retrofit decisions. Airflow and static pressure show whether the fan is delivering against the actual system resistance. Fan speed, motor current, and power consumption show how hard the equipment is working to do it. Supply and return air temperatures, along with temperature rise across the space, help determine whether the problem is fan performance, air distribution, or a heat load that has outgrown the original design assumptions.<\/p>\n\n\n\n

The fan curve adds another layer to that review. Axial and centrifugal fans respond differently as resistance changes, so the operating point matters as much as the nameplate capacity. Axial fans are especially sensitive to operation in the stall region of the curve, where airflow can become unstable and turbulence can increase vibration, performance inconsistency, and mechanical stress on the motor and impeller. When a facility runs hot, raising fan speed may only treat the symptom. The stronger question is whether the fan is operating in a stable, efficient part of the curve for the system as it exists.<\/p>\n\n\n

\n
\"\"<\/a>
Temperature, pressure, and airflow feedback can help the system respond to changing demand<\/em><\/figcaption><\/figure>\n<\/div>\n\n\n

Constant-speed fans limit temperature control<\/strong><\/p>\n\n\n\n

Legacy constant-speed fan systems are usually designed around a single operating point. That can work when the heat load, airflow path, and pressure requirements remain stable, but they become less effective when equipment density changes, heat becomes concentrated in different locations, or the facility needs to respond to changing demand throughout the day. <\/p>\n\n\n\n

A constant-speed fan has limited ability to follow those changes. It may waste energy during low demand periods while still lacking the control needed to respond when heat concentrates in a specific area. In many constant-speed systems, control comes from cycling the fan on and off or using dampers to restrict airflow. Both approaches can influence temperature, but neither allows the fan to continuously adjust its speed based on temperature, pressure, or airflow feedback.<\/p>\n\n\n\n

Variable-speed operation changes this relationship. Instead of forcing the fan system to run around one fixed condition, speed modulation allows the fan to respond to what the facility needs. When the heat load rises, fan speed can increase and when demand falls, fan speed can decrease. This gives the system a better chance of maintaining stable temperature while reducing unnecessary energy use.<\/p>\n\n\n\n

Electronically commutated fans, commonly referred to as EC fans, integrate motor and control capability into a single high efficiency package. Unlike a traditional AC motor driven fan that may require an external variable frequency drive to adjust performance, an EC fan can speed up or slow down based on the control signal it receives from the system. That makes it useful in applications where temperature, pressure, or airflow requirements change over time.<\/p>\n\n\n\n

The energy advantage comes from avoiding unnecessary full speed operation. A fan that only needs partial output should not have to run as if peak demand is always present. By matching speed more closely to the load, EC fan systems can support temperature stability while reducing power consumption. The same control capability can also simplify system response when sensors detect higher pressure drop, blocked airflow, or a heat load that has moved beyond the original design assumption.<\/p>\n\n\n

\n
\"\"<\/a>
ZIEHL-ABEGG works in fan, motor, and control technology for applications where airflow performance, efficiency, noise, reliability, and serviceability all must be considered together<\/em><\/figcaption><\/figure>\n<\/div>\n\n\n

Fan type should match the resistance profile<\/strong><\/p>\n\n\n\n

Fan selection should be tied to the pressure and airflow requirements of the application, not only to the size of the facility or the general desire for more cooling. Those requirements determine whether the system needs a fan built primarily to move large volumes of air or one designed to push air through higher resistance. That distinction is where axial and centrifugal fans begin to separate. <\/p>\n\n\n\n

Axial fans are strong choices when the application requires high air volume at relatively low static pressure. They are commonly used in applications such as condenser sections, rooftop equipment, and other systems where air is pulled through coils and discharged to the atmosphere. Their strength is moving a large volume of air efficiently when the resistance path is not overly complex.<\/p>\n\n\n\n

Centrifugal fans are better suited to applications with higher resistance. Ductwork, filters, coils, turns, and more complex airflow paths all increase pressure requirements. In those systems, the fan must be able to push air through the resistance created by the installed components. Selecting an axial fan for an application that behaves like a high resistance system can leave the facility short on delivered airflow even if the fan appears large enough on paper.<\/p>\n\n\n\n

Fan arrays add another design option, especially where redundancy matters. A single large fan can create a single point of failure. If that fan goes down, the facility may lose a major portion of its airflow and quickly develop temperature problems. An array of smaller fans can provide more flexibility because the system may continue operating at reduced capacity if one fan fails. In equipment dense environments, that redundancy can be important for uptime, process stability, and thermal protection.<\/p>\n\n\n\n

Control is also easier to refine with an array. Multiple electronically commutated (EC) fans can be staged or modulated to match changing demand rather than forcing one large fan to serve every operating condition. This can improve both controllability and serviceability, particularly in retrofit projects where downtime, access, and available space affect the final design.<\/p>\n\n\n\n

Before the retrofit, define the heat problem<\/strong><\/p>\n\n\n\n

New fans can improve performance, but they will not solve every overheating issue on their own. Before committing to a retrofit, facility teams should define the specific problem they are trying to correct. The most useful starting point is determining whether the issue is insufficient airflow, excessive static pressure, poor air distribution, inadequate control, rising heat load, or aging equipment that no longer operates as intended.<\/p>\n\n\n\n

The same measurements used in diagnosis should guide the retrofit decision. Those values show whether the existing system is failing to deliver required performance or whether the facility\u2019s requirements have changed. They also help determine whether a fan upgrade alone is enough or whether a specific variable needs attention.<\/p>\n\n\n\n

EC fan technology can be a strong retrofit path when the facility needs better speed control, higher efficiency, simplified wiring, or improved redundancy. In many cases, the fan, motor, and control capability are integrated in a compact package, reducing some of the external components associated with AC motor and VFD arrangements. For facility teams working within downtime and budget constraints, that integration can make upgrades easier to plan and implement.<\/p>\n\n\n\n

That is also where supplier expertise becomes important. ZIEHL-ABEGG works in fan, motor, and control technology for applications where airflow performance, efficiency, noise, reliability, and serviceability all must be considered together. Rather than treating the fan as a standalone replacement part, the company\u2019s approach centres on matching the fan system to the operating environment, including the resistance profile, control requirements, installation constraints, and long term maintenance expectations. That application specific focus can help facility teams avoid retrofits that look appropriate on paper but fail to correct the underlying thermal problem.<\/p>\n\n\n\n

Still, the value of any retrofit depends on matching the technology to the real operating condition. If the system is hot because filters are loaded, return paths are restricted, or airflow is not reaching the heat source, replacing fans without correcting those issues may leave the root cause in place. A successful retrofit should improve control of the actual thermal problem, not just modernise the equipment list.<\/p>\n\n\n\n

Smart fan systems are becoming more application specific<\/strong><\/p>\n\n\n\n

As cooling demand continues to rise, fan system design is moving toward higher efficiency motors, more connected controls, improved serviceability, and more refined air performance. Sensor based control gives facilities a way to react to real conditions rather than operating around fixed assumptions. Temperature, pressure, and airflow feedback can help the system respond to changing demand while also revealing developing problems, such as filter loading, blocked airflow paths, or changes in system resistance.<\/p>\n\n\n\n

ZIEHL-ABEGG\u2019s work reflects that broader movement toward integrated, application specific fan performance. Its EC fan systems combine motor efficiency, speed modulation, and controllability in a compact package suited to facilities where air demand changes over time. The company also differentiates itself through its engineering depth in aerodynamics and acoustic performance. Its biomimetic fan designs, for example, draw from natural airflow patterns to reduce noise and improve air movement. One axial impeller design uses a serrated trailing edge inspired by the barn owl, whose quiet flight characteristics help inform blade geometry that disrupts acoustic patterns as air leaves the impeller.<\/p>\n\n\n\n

The next generation of facility cooling will not be defined by airflow volume alone. The strongest systems will be those that deliver the right air, at the right speed, through the right path, with enough intelligence to adjust as conditions change. For facility teams, that shifts the retrofit conversation away from a simple equipment swap and toward a more disciplined evaluation of heat load, pressure, distribution, control, and service access.<\/p>\n\n\n\n

Persistent heat problems rarely come from one variable. They are usually the result of several conditions working together. A better fan system can help, but only when it is selected as part of a broader understanding of how heat actually moves through the facility. When teams diagnose the problem first and retrofit around the real operating condition, cooling upgrades become more than a reaction to hot spots. They become a way to improve efficiency, reliability, and control across the space.<\/p>\n\n\n\n

Joshua Baxely is Technical Sales Rep., Global Key Accounts at ZIEHL-ABEGG<\/a><\/strong>.<\/p>\n","protected":false},"excerpt":{"rendered":"

Joshua Baxely explains how persistent facility hot spots can result from airflow distribution, system resistance, fan controls, and changing heat loads, highlighting electronically commutated (EC) fans, variable-speed control, and fan arrays as potential solutions. This is relevant to industrial facilities because equipment-heavy production environments can generate significant and changing heat loads, making effective airflow, energy-efficient …<\/p>\n","protected":false},"author":1,"featured_media":33787,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[199,1],"tags":[15611,1410,15612,1574,15243],"class_list":["post-33785","post","type-post","status-publish","format-standard","has-post-thumbnail","","category-news-views-and-opinion","category-process","tag-airflow","tag-fans","tag-smart-fans","tag-ventilation","tag-ziehl-abegg"],"yoast_head":"\nHot spots usually start with an airflow problem - Engineer News Network<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.engineernewsnetwork.com\/blog\/hot-spots-usually-start-with-an-airflow-problem\/\" \/>\n<meta property=\"og:locale\" content=\"en_GB\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Hot spots usually start with an airflow problem - Engineer News Network\" \/>\n<meta property=\"og:description\" content=\"Joshua Baxely explains how persistent facility hot spots can result from airflow distribution, system resistance, fan controls, and changing heat loads, highlighting electronically commutated (EC) fans, variable-speed control, and fan arrays as potential solutions. 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